Blister Package Notched Line Pull Tab Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Blister packaging using non-brittle materials like polyesters faces challenges with score depth consistency and knife wear, making it difficult to reliably open, and is costly due to the need for sharp knives and precise cuts.
Innovation Solution
A novel pull tab configuration with a notched line that includes alternating severed and unsevered portions, allowing for reliable breaking without requiring brittle materials like PVC, and reducing manufacturing steps and costs by forming the notched line in the same mold as the recessed product cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brittle PVC material is used with score line, then reliable breaking is achieved, but manufacturing precision and knife wear become problematic
Solution Approach 1:
The score line is segmented into alternating severed and unsevered portions, creating a notched line pattern. This segmentation allows the package to break reliably at the severed portions while the unsevered portions maintain structural integrity and guide the break, eliminating the need for consistent deep scoring across the entire line.
Solution Approach 2:
Different portions of the score line have different qualities: some portions are completely severed (100% depth) while others are partially severed (less than 100% depth). This local variation in cut depth creates predictable break points while maintaining overall line integrity, resolving the contradiction between reliable breaking and manufacturing precision.
2Adaptability or versatility
If non-brittle materials like polyester are used, then recyclability improves, but breaking reliability deteriorates
Solution Approach 1:
The notched line with alternating severed and unsevered portions creates inherent weak points in the material structure. This segmentation allows non-brittle materials like polyester to break reliably at the severed portions when bent, enabling the use of recyclable materials without sacrificing breaking reliability.
Solution Approach 2:
The score line is pre-formed during package manufacturing with alternating cut patterns. This preliminary action creates predetermined break points that will fail in a controlled manner during use, allowing non-brittle materials to break reliably without requiring the material to be inherently brittle.
3Reliability
If deep score cuts are made to ensure breaking, then breaking reliability improves, but knife wear and manufacturing cost increase
Solution Approach 1:
Instead of cutting through the entire thickness at every point along the score line, the invention uses partial cuts (unsevered portions) at alternating intervals. This partial action is sufficient to create reliable breaking points while significantly reducing knife wear and manufacturing costs compared to complete cuts throughout.
Solution Approach 2:
The score line is divided into segments of different cut depths. The severed portions provide breaking points while the unsevered portions reduce the total cutting required, lowering manufacturing costs and knife wear while maintaining breaking reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable and cost-effective opening of blister packages using a variety of base substrate materials, improving score depth consistency and reducing knife wear, while allowing for the use of less brittle polymers and simpler manufacturing processes.
Implementation Method 1
an edge portion of the package can be bent back by the user along a reduced thickness score line, breaking the brittle PVC base substrate along the score line to form a tab
Data Source
Figure 1
Figure 2A~2B
Figure 2C
AI summary
A blister package and method of manufacture are provided, the package including a novel pull tab configuration for opening an individual product compartment of the package. According to one embodiment the blister package includes: a thermoformed plastic base substrate 12 having a thickness, the base substrate 12 having at least one thermoformed recessed product cavity 16 to retain product therein and an associated sealing surface area 23 surrounding the product cavity 16, a peelable cover layer 14 removably attached to the base substrate 12 comprising a first portion covering the product cavity and a second portion overlapping and sealed to the surrounding sealing surface area, the base substrate 12 having a notched line 17 extending across the sealing surface area between two points on a perimeter of the sealing surface area 23 and spaced from the product cavity 16, the notched line 17 including alternating severed and unsevered line portions, the severed line portions extending completely through the thickness of the base substrate 12 while the unsevered line portions comprise connected portions; wherein a portion of the base substrate 12 is configured to be bent and broken off by a user at the notched line to form a pull tab that includes the broken off portion of the base substrate and the cover layer sealed thereto, enabling a user grasping the pull tab to peel back and separate the cover layer from the sealing surface area surrounding the product cavity to enable release of a product from the product cavity.